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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Composite Lithium Metal Structure to Mitigate Pulverization and Enable Long‐Life Batteries

In lithium metal batteries, non‐uniform stripping of lithium results in pit formation, which promotes subsequent non‐uniform, dendritic deposition. This viscous cycle leads to pulverization of lithium which promotes cell shorting or capacity degradation, symptoms further exaggerated by high electrode areal loading and lean electrolytes. Here, to address this challenge, a composite lithium metal anode is engineered that contains uniformly distributed, nanometer‐sized carbon particles. This composite lithium is shown to strip more uniformly since the growth of non‐uniform pits is intercepted by the carbon particles. This mechanism is corroborated by a continuum electrochemical model. Subsequent lithium deposition on carbon particles is also found to be more uniform than on the surface with irregular pits. Notably, the pulverization rate of composite lithium is 26 times slower than that of commercial lithium. Moreover, in a Li‐S battery with sulfurized polyacrylonitrile cathode, the use of the composite anode extends the cycle life by three times when the areal capacity is 8 mAh cm −2 . The approach of using an engineered lithium composite structure to address challenges during both stripping and plating can inform future designs of lithium metal anodes for high areal capacity operations.

high areal capacity↗
DOE OSTI2023

Fluorinated High-Voltage Electrolytes To Stabilize Nickel-Rich Lithium Batteries

As state-of-the-art (SOA) lithium-ion (Li-ion) batteries approach their specific energy limit (~250 Wh kg -1 ), layer-structured, nickel-rich (Ni-rich) lithium transition metal oxide-based cathode materials, e. g., LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC811), have attracted great interest owing to their practical high specific capacities (>200 mAhg -1 ). Coupled with their high average discharge voltages (~4 V vs Li/Li + ), Ni-rich cathode-based lithium batteries possess a great potential to achieve much higher specific energies (>350 Wh kg -1 at the cell level) than the SOA Li-ion counterparts. In addition, Ni-rich oxides are low-cost battery cathode materials due to their low cobalt contents. However, Ni-rich cathode-based lithium batteries suffer quick capacity degradations upon cycling, particularly at high upper cutoff voltages (e.g., ≥= 4.5 V vs Li/Li + ), due to crystal structure changes of the active cathode materials and parasitic side reactions at the electrolyte/electrode interfaces. In this study, a fluorinated-solvent-based, high-voltage stable electrolyte (HVE), i.e., 1 M Li bis(trifluoromethanesulfonyl)imide (LiTFSI) in fluoroethylene carbonate (FEC), bis(2,2,2-trifluoroethyl) carbonate (FDEC), and methyl (2,2,2-trifluoroethyl) carbonate (FEMC) with Li difluoro(oxalate)borate (LiDFOB) additive, was formulated and evaluated in Li/NMC811 battery cells. Further, to the best of our knowledge, this class of electrolyte has not been investigated for Ni-rich cathode-based lithium batteries. Li/NMC811 cells with HVE exhibited a superior long-term cycle performance stability, maintaining ~80% capacity after ~500 cycles at a high cutoff voltage of 4.5 V (vs Li/Li + ) than a baseline carbonate-solvent-based electrolyte (BE). The superior cycle stability of the Li/NMC811 cells is attributed to the inherently high-voltage stability of HVE, supported by the physical and electrochemical analyses. This conclusion is supported by our density functional theory (DFT) modeling where HVE shows a less tendency of deprotonation/oxidation than BE, leading to the observed cycle stability. The findings in this study are important to help tackle the technical challenges facing Ni-rich cathode-based lithium batteries to realize their high energy density potentials with a long cycle life.

25 ENERGY STORAGE↗
DOE OSTI2025

In-Situ FTIR Detection of Transition Metal (TM)-Ion Dissolution From Cathodes in Li-Ion Batteries

Transition metal (TM) ions, commonly Ni and Mn, play a crucial role in Li-ion battery cathodes as the reaction centers for rapid redox reactions. A major challenge with TM-based cathodes is capacity degradation, particularly at higher operating voltages. This degradation is closely linked to the dissolution of TMs from the cathode materials and their subsequent deposition on the anode. This process not only modifies the surface structure of the cathode but, more significantly, alters the SEI composition on the anode [1-2]. The dissolution of TMs cations into a liquid electrolyte from cathode materials, such as Mn-ion dissolution from Mn-rich cathode (LMR), is detrimental to the cycling performance of Li-ion batteries [3-4]. Much attention has been paid to this issue but there remains a lack of characterization techniques which can detect the TM-ion dissolution from the cathode during electrochemical measurements. In our study, we use in-situ ATR-FTIR as an effective technique to probe the TM-ion dissolution from the cathode. We have first demonstrated the detrimental effects of TM ions on the electrochemical performance of Li-ion batteries by adding a small amount of TM salt (50 mM Mn(PF6)) to the electrolyte of a Li-ion coin cell with LFP and graphite electrode. We observed a rapid capacity fade after the first delithiation cycle. To investigate TM ion dissolution, we established a baseline IR spectrum for various TM solvation states (such as Mn and Ni) by measuring concentration-dependent IR spectra. This baseline spectrum helps us detect TM ion dissolution during battery cycling. In this work, we discuss in detail the effect of TM ions on the electrochemical performance of Li-ion batteries and the detection of TM ions during battery cycling using in-situ FTIR spectroscopy. We will compare TM dissolution between coated and uncoated cathodes to examine the effect of cathode coatings to mitigate degradation due to TM dissolution and cross-over from cathode to anode. References: (1) Zhan, C.; Wu, T.; Lu, J.; Amine, K. Dissolution, migration, anddeposition of transition metal ions in Li-ion batteries exemplified byMn-based cathodes - a critical review. Energy Environ. Sci. 2018, 11,243-257. (2) Jung, R.; Linsenmann, F.; Thomas, R.; Wandt, J.; Solchenbach,S.; Maglia, F.; Stinner, C.; Tromp, M.; Gasteiger, H. A. Nickel,Manganese, and Cobalt Dissolution from Ni-Rich NMC and TheirEffects on NMC622-Graphite Cells. J. Electrochem. Soc. 2019, 166,A378-A389. (3) Zhao, L.; Chenard, E.; Capraz, O. O.; Sottos, N. R.; White, S.R. Direct Detection of Manganese Ions in Organic Electrolyte by UV-Vis Spectroscopy. J. Electrochem. Soc. 2018, 165, A345-A348 (4) Zhang, Y.; Hu, A.; Xia, D.; Hwang, S.; Sainio, S.; Nordlund, D.;Michel, F. M.; Moore, R. B.; Li, L.; Lin, F. Operando characterization and regulation of metal dissolution and redeposition dynamics nearbattery electrode surface. Nat. Nanotechnol. 2023, 18, 790.

25 ENERGY STORAGE↗
DOE OSTI2024

Surface Atomic Rearrangement with High Cation Ordering for Ultra-Stable Single-Crystal Ni-Rich Co-Less Cathode Materials

It is crucial to minimize cobalt content in Ni-rich layered single-crystal cathodes due to their high price and limited availability, yet it will inevitably lead to cation disordering, capacity degradation, and thermal issues. Herein, to overcome the intrinsic trade-off between performance and composition of Ni-rich Co-less single-crystal cathodes, a precursor engineering strategy with an epitaxially grown cobalt enrichment on the surface is innovatively proposed. In contrast to traditional coating modifications with random orientation and rigid surface-bulk boundary, the epitaxially enriched surface cobalt layer on the precursor undergoes rapid interdiffusion with the internal Ni 3+ during the optimized sintering process. This interdiffusion eliminates the surface-bulk boundary, promoting the uniform distribution of cobalt and synergistically addressing the Li/Ni intermixing. Moreover, an enhanced surface Li + diffusion is obtained, thereby suppressing the Li + concentration gradient and intragranular cracks generation. Consequently, the modified LiNi 0.7 Co 0.07 Mn 0.23 O 2 exhibits impressive cycling stability with increased capacity retention in both coin-type half-cells and pouch-type full-cells (91% after 1000 cycles), even under the harsh condition of high-temperature, surpassing the majority of previously reported Ni-rich cathodes. Finally, this work opens new avenues toward the low cost, high energy density, thermal stability, and long cyclic life for Ni-rich Co-less cathodes and sheds light on large-scale commercial production.

25 ENERGY STORAGE↗
DOE OSTI2025

Multi-stage heat pump with two-phase injection for cold climate applications implementing natural refrigerants

Heat pump adoption in cold climates is limited by various technical challenges, including heat capacity degradation, compressor deterioration, and frost accumulation on the outdoor heat exchanger. Furthermore, wide-spread adoption of heat pumps with high global warming potential presents a possible environmental concern. Thus, we present a heat pump concept termed the “saturation cycle,” which uses numerous compression stages to improve energy efficiency and injects two-phase refrigerant between compression stages to dramatically reduce compressor discharge temperatures. Given the growing interest in heat pumps, there is a need for a straightforward framework for parametric evaluation of natural refrigerants in high-efficiency heat pump cycle architectures, like the saturation cycle, in adverse climates. This work develops a thermodynamic modeling framework and focuses on the application of natural refrigerants to explore the performance trends at extremely cold climates down to −25 °C. This study shows that a two-stage saturation cycle and four-stage saturation cycle can reduce the compressor discharge superheating by up to 51–57 % or 73–80 %, respectively, depending on the refrigerant. Furthermore, at −25 °C, a two-stage R-290 saturation cycle heat pump theoretically can use 25 % less power than a single-stage heat pump or can provide up to 59 % more heating capacity when using the same compressor power as the baseline single-stage heat pump. The exergetic parametric analyses show that two-phase refrigerant injection fundamentally improves the thermodynamic performance of the heat pump, reducing overall exergy destruction by 10 % compared to a vapor-injection heat pump, compared at −25 °C. Thus, the saturation cycle is a promising heat pump cycle architecture for cold climate applications due to its superior energy savings (or capacity improvement) and substantial de-superheating capabilities.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Altered Expression of Two Small Secreted Proteins (ssp4 and ssp6) Affects the Degradation of a Natural Lignocellulosic Substrate by Pleurotus ostreatus

Pleurotus ostreatus is a white-rot fungus that can degrade lignin in a preferential manner using a variety of extracellular enzymes, including manganese and versatile peroxidases (encoded by the vp1-3 and mnp1-6 genes, respectively). This fungus also secretes a family of structurally related small secreted proteins (SSPs) encoded by the ssp1-6 genes. Using RNA sequencing (RNA-seq), we determined that ssp4 and ssp6 are the predominant members of this gene family that were expressed by P. ostreatus during the first three weeks of growth on wheat straw. Downregulation of ssp4 in a strain harboring an ssp RNAi construct (KDssp1) was then confirmed, which, along with an increase in ssp6 transcript levels, coincided with reduced lignin degradation and the downregulation of vp2 and mnp1. In contrast, we observed an increase in the expression of genes related to pectin and side-chain hemicellulose degradation, which was accompanied by an increase in extracellular pectin-degrading capacity. Genome-wide comparisons between the KDssp1 and the wild-type strains demonstrated that ssp silencing conferred accumulated changes in gene expression at the advanced cultivation stages in an adaptive rather than an inductive mode of transcriptional response. Based on co-expression networking, crucial gene modules were identified and linked to the ssp knockdown genotype at different cultivation times. Based on these data, as well as previous studies, we propose that P. ostreatus SSPs have potential roles in modulating the lignocellulolytic and pectinolytic systems, as well as a variety of fundamental biological processes related to fungal growth and development.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Improving Ionic Conformality Across Polymer Electrolyte|Electrode Interfaces

Maintaining uniform ionic transport at electrode|electrolyte interfaces, i.e., ionic conformality, remains challenging in polymer electrolyte (PE)-based solid-state batteries. Morphological conformality does not necessarily imply ionic conformality. In PEs, which typically consist of a mechanically supporting component and distinct ionically conductive components, the rearrangement or depletion of mobile ion-conductive domains at interfaces can disrupt ionic transport pathways. Such localized ionic depletion contributes to interfacial instability and capacity degradation in high-voltage lithium-metal batteries. Herein, an electrolyte design approach aimed at minimizing interfacial heterogeneities is demonstrated through compositional adjustments, characterized by spatially resolved structural and chemical X-ray techniques and NMR diffusometry to elucidate ion transport dynamics. This approach improves ionic conformality at electrode interfaces, enhancing cycling stability in Li||LiNi 0.8 Co 0.1 Mn 0.1 O 2 (NMC811) coin and pouch cells cycled at high voltages. These results contribute to understanding interfacial behaviors in multiphase PEs and inform strategies for improving stability across solid-state battery interfaces.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A Nanoscale Ternary Amide‐rGO Composite with Boosted Kinetics for Reversible H 2 Storage

Abstract Metal amides are attractive candidates for hydrogen storage due to their high volumetric and gravimetric hydrogen densities. However, the sluggish kinetics and competing side reactions during hydrogen uptake and release limit their practical use. Here, a novel nanoconfined Li 2 Mg(NH) 2 @reduced graphene oxide (rGO) composite is presented, which is fabricated using a melt‐infiltration method with a minimum weight penalty of only 2 wt.%. The presence of rGO ensures close contact between the active phases, effectively preventing aggregation during cycling process. As a result, the reversible capacity of Li 2 Mg(NH) 2 @rGO reaches 4.42 wt.%, with no capacity degradation observed after multiple cycling. Theoretical calculations show that rGO catalyzes the hydrogen bond cleavage at the Mg‐amide/Li hydride interface, leading to local dehydrogenation hotspots and significantly improves kinetics of dehydrogenation compared to the bulk counterpart. This study provides a promising strategy for designing metal imide‐based composites to overcome the kinetic limitations and improve their reversible hydrogen storage performance.

08 HYDROGEN↗
DOE OSTI2024

Strategically Modified Ligand Incorporating Mixed Phosphonate and Carboxylate Groups to Enhance Performance in All-Iron Redox Flow Batteries

Iron redox flow batteries (Fe-RFBs) hold significant promise for achieving cost-effectiveness and utilizing abundant materials for stationary energy storage applications. Here, a design of a novel Fe complex utilizing a nitrogenous phosphonate/carboxylate mixed ligand, N,N-Bis(phosphonomethyl)glycine (BMPG), is presented to achieve high performance Fe anolyte. Compared to its all-phosphonate form, nitrilotri(methylphosphonic acid) (NTMPA), the new complex Fe(BPMG) 2 demonstrates a negatively shifted redox potential, resulting in ≈0.07 V (≈10%) increase in battery output voltage. Full battery testing paired with ferrocyanide catholyte demonstrates stable cycling (capacity degradation <0.0001%/cycle) over 730 consecutive charge/discharge cycles with Coulombic Efficiency of 100% at a current density of 20 mA cm -2 under near neutral pH (≈8). Of particular interest, density functional theory (DFT) studies and operando Raman measurements provide strong evidence supporting a molecular structure in BPMG, which reveals the mixed phosphonate/carboxylate groups in BPMG maintain the octahedral coordination of the Fe ion center with phosphonates exclusively, while leaving the carboxylate unbound for both Fe(II) and Fe(III) complexes. This structural similarity between BPMG-based Fe(II) and Fe(III) complexes effectively mitigates the slow redox reaction kinetics observed in Fe(NTMPA) 2 anolyte, where significant ligand reorientation occurs between Fe(II) and Fe(III) complexes.

25 ENERGY STORAGE↗
DOE OSTI2023

Suppressing Universal Cathode Crossover in High‐Energy Lithium Metal Batteries via a Versatile Interlayer Design**

Abstract The universal cathode crossover such as chemical and oxygen has been significantly overlooked in lithium metal batteries using high‐energy cathodes which leads to severe capacity degradation and raises serious safety concerns. Herein, a versatile and thin (≈25 μm) interlayer composed of multifunctional active sites was developed to simultaneously regulate the Li deposition process and suppress the cathode crossover. The as‐induced dual‐gradient solid‐electrolyte interphase combined with abundant lithiophilic sites enable stable Li stripping/plating process even under high current density of 10 mA cm −2 . Moreover, X‐ray photoelectron spectroscopy and synchrotron X‐ray experiments revealed that N‐rich framework and CoZn dual active sites can effectively mitigate the undesired cathode crossover, hence significantly minimizing Li corrosion. Therefore, assembled lithium metal cells using various high‐energy cathode materials including LiNi 0.7 Mn 0.2 Co 0.1 O 2 , Li 1.2 Co 0.1 Mn 0.55 Ni 0.15 O 2 , and sulfur demonstrate significantly improved cycling stability with high cathode loading.

Xie, Chuyi↗
DOE OSTI2023

Suppressing Universal Cathode Crossover in High‐Energy Lithium Metal Batteries via a Versatile Interlayer Design**

Abstract The universal cathode crossover such as chemical and oxygen has been significantly overlooked in lithium metal batteries using high‐energy cathodes which leads to severe capacity degradation and raises serious safety concerns. Herein, a versatile and thin (≈25 μm) interlayer composed of multifunctional active sites was developed to simultaneously regulate the Li deposition process and suppress the cathode crossover. The as‐induced dual‐gradient solid‐electrolyte interphase combined with abundant lithiophilic sites enable stable Li stripping/plating process even under high current density of 10 mA cm −2 . Moreover, X‐ray photoelectron spectroscopy and synchrotron X‐ray experiments revealed that N‐rich framework and CoZn dual active sites can effectively mitigate the undesired cathode crossover, hence significantly minimizing Li corrosion. Therefore, assembled lithium metal cells using various high‐energy cathode materials including LiNi 0.7 Mn 0.2 Co 0.1 O 2 , Li 1.2 Co 0.1 Mn 0.55 Ni 0.15 O 2 , and sulfur demonstrate significantly improved cycling stability with high cathode loading.

25 ENERGY STORAGE↗
DOE OSTI2025

On the dynamics of the fluoroethylene carbonate generated solid electrolyte interphase on silicon anodes during calendar life aging

Here, the widespread use of silicon (Si)-rich anodes in lithium-ion batteries (LIBs) is impeded by an unstable solid electrolyte interphase (SEI) incurring insufficient cell life. Fluoroethylene carbonate (FEC) additive in the electrolyte significantly improves cycle life. However, the gains on calendar life remain unclear; the SEI structure still undergoes detrimental alterations at rest. Thus, elucidating the SEI dynamics during calendar aging is critical to mitigating time-dependent capacity degradation. ATR-FTIR, XPS, and ToF-SIMS are used herein to investigate the SEI structure before and after calendar aging. Si cycled without FEC exhibits no notable SEI chemistry changes Pre- and Post-aging, leaving poor passivation as the main failure pathway. Conversely, the FEC-SEI starts as short oligomeric species from FEC/EC electroreduction prior to aging; after calendar aging, polymerized carbonates become consistently more prominent. Unexpectedly, the deposition of self-polymerized FEC species results from time exposure to the delithiated Si specifically as opposed to the lithiated surface. This unexpected finding is supported by another recent Si calendar-aging research, which albeit not investigating FEC, finds global failure of the SEI upon delithiation resulting in ∼247 fold more reactive surface compared to the lithiated.

Batteries↗
DOE OSTI2024

Mesoscale interplay among composition heterogeneity, lattice deformation, and redox stratification in single-crystalline layered oxide cathode

Single-crystalline layered oxide materials for lithium-ion batteries are featured by their excellent capacity retention over their polycrystalline counterparts, making them sought-after cathode candidates. Their capacity degradation, however, becomes more severe under high-voltage cycling, hindering many high-energy applications. It has long been speculated that the interplay among composition heterogeneity, lattice deformation, and redox stratification could be a driving force for the performance decay. The underlying mechanism, however, is not well-understood. In this study, we use X-ray microscopy to systematically examine single-crystalline NMC particles at the mesoscale. This technique allows us to capture detailed signals of diffraction, spectroscopy, and fluorescence, offering spatially resolved multimodal insights. Focusing on early high-voltage charging cycles, we uncover heterogeneities in valence states and lattice structures that are inherent rather than caused by electrochemical abuse. These heterogeneities are closely associated with compositional variations within individual particles. Our findings provide useful insights for refining material synthesis and processing for enhanced battery longevity and efficiency.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Machine learning based prediction of airflow maldistribution in air-to-refrigerant heat exchangers

Flow maldistribution is a common challenge in heat exchanger (HX) design and particularly important for air-to-refrigerant geometries where capacity losses can approach 65%. This has a major impact on central air conditioning systems, as compact duct design motivates the use of A-type HXs which are known to be affected by airflow maldistribution. Because velocity profiles are difficult to predict, components are often oversized leading to increased material cost, system footprint, and refrigerant charge. Several studies detail airflow maldistribution for individual HXs and packages, but findings cannot always be extrapolated to new designs. In this work, a machine learning (ML) based flow profile prediction framework is developed and applied to two common package configurations: (i) A-type and (ii) U-type HXs, across a broad range of HX geometries and flow rates. Porous media CFD simulations are validated against independent data for both package types as well as comprehensive in house measurements for a finless geometry with shape optimized non-round tubes, which validates the framework for new heat transfer surfaces. The ML models are trained on the porous media CFD simulations, predicting volumetric flow rate (VFR) within 1.1% and 1.9% with maximum relative L 2 norm errors of 0.48 and 0.65, respectively, while also delivering 10 5 speed up factor compared to full porous media CFD. HX level simulations show an up to 9% reduction in heat transfer from flow maldistribution, with greater losses occurring at smaller half apex angles. This framework enables rapid and highly accurate prediction of airflow maldistribution induced capacity degradation.

42 ENGINEERING↗
DOE OSTI2020

Evolution of the Rate-Limiting step: From Thin Film to Thick Ni-rich Cathodes

Ni-rich NMC (LiNixMnyCo1-x-yO2, x = 0.6) has the attributes of high specific capacity (greater than 180 mAh g-1), high operating voltage (ca. 3.8 V) and low cost, which is therefore deemed as one of the most promising cathode candidates for next-generation high-energy Li-ion batteries (LIBs). However, challenges exist before the large-scale commercialization of Ni-rich cathode such as gas generation, capacity degradation especially at high rate or elevated temperatures. From thin film to densely pack high loading cathode, this work investigates the rate-limiting steps in Ni-rich cathodes e.g., phase structure, electronic and ionic conductivity to understand the reaction kinetics at different scales. This work provides new insights in understanding the electrochemical properties of Ni-rich cathode at different levels to inspire revolutionary ideas to address the fundamental issues of Ni-rich cathode from materials to relevant electrode levels.

Hu, Jiangtao↗
DOE OSTI2022

Mechanistic insights into structural parameters maximizing energy storage density in Si mesoporous electrodes for Li-ion batteries

Mesoporous Si electrodes have an interesting set of structural parameters, which, when carefully optimized, can lead to ultrahigh energy density Si electrodes for Li-ion batteries. We present here in this paper details of a systematic research leading to the discovery of an “ideal” structure of mesoporous Si electrode, which results in exceptional cracking/damage resistance, while simultaneously having very high specific (>2000 mAh g-1) and total (>1.5 mAh cm-2) capacities for large number of cycles. The electrodes near the “ideal” value of the characteristic structural parameter (the ratio of Si wall thickness to pore diameter) are free from first-cycle capacity degradation, and are efficient in accommodating the volume changes during lithiation by uniformly filling up the porous space between Si walls. Interestingly, these electrodes are also found to be structurally damage-resistant, surviving through many lithiation-delithiation cycles. Using charge-discharge cycling and electron microscopy we show that ideal structure is the key for achieving ultrahigh energy storage density in Si mesoporous electrodes for Li-ion batteries.

25 ENERGY STORAGE↗
DOE OSTI2021

Toward the Understanding of the Reaction Mechanism of Zn/MnO2 Batteries Using Non-alkaline Aqueous Electrolytes

Zn/MnO 2 systems using non-alkaline aqueous electrolytes have attracted tremendous interest as rechargeable aqueous Zn ion batteries due to their safety and high specific capacities. Despite their promising electrochemical performance, however, their reaction mechanism has remained elusive. Here in this paper, we examined the structural evolution of cryptomelane α-MnO 2 cathode by ex situ transmission electron microscopy after electrochemical testing using two different non-alkaline aqueous Zn electrolytes with acetate and triflate salts of different pH values. We have discovered that the systems tested in both electrolytes exhibit a dissolution–deposition reaction mechanism through dissolution–deposition of Mn 2+ ions from/on the cathodes with a display of similar discharge/charge product formation. We have also found that the cell tested using the acetate electrolyte shows evidence of structural irreversibility that might contribute to its rapid capacity degradation. This finding offers an important insight into optimizing the cathode design for enhanced electrochemical function of aqueous Zn/MnO 2 batteries.

25 ENERGY STORAGE↗
DOE OSTI2024

3D Printed Nanoporous Separators Based on Polymerization-Induced Phase Separation for Fast-Charging, High Cycling Stability Li-Ion Batteries

Fast charging and stable lithium-ion batteries (LIBs) require prompt Li ion transport between electrodes. 3D porous separators can potentially improve ion transport at both the microscale and macroscale levels. Additive manufacturing (AM) is an ideal tool to produce and study 3D porous separators of LIBs, although little work has been reported in this area. Here, we demonstrate porous structural control in layer-by-layer printed hexanediol diacrylate (HDDA) separators using a projection micro stereolithography (PμSL) AM technology and present their corresponding battery performance in lithium nickel manganese cobalt oxide (NMC)/graphite full cells. The composition of photocurable resin determines the porous morphology (e.g., bicontinuous and droplet-like), while the settings of printing layer thickness and number of exposures can be used to adjust the porosity (e.g., from 27% to 63%). Optimal resin and print conditions are determined, and the resulting separator exhibits superior Li ion conductivity and therefore higher rate performance and longer cycling life. Compared with a Celgard 2325 separator, the optimized porous HDDA separator increases the 10C-rate capacity by 34% and decreases the capacity degradation rate at the 1C-rate by 4.9%. In conclusion, this work paves the way for future AM of 3D separators for high-energy, high-power, and long-cycling-life LIBs.

25 ENERGY STORAGE↗